Expanded Metal LWO

ABSTRACT

A filter assembly that has a filtering method overlying an expanded metal skeletal structure, said expanded metal employing sidewalls that are Long Way of the Diamond having their greatest length parallel to a roofs edge and whose sidewall members have a top edge facing oncoming water flow that is narrow than a corresponding bottom edge.

This application is related to U.S. Ser. No. 13/400,229 Abandoned

When considering any prior art in field 52/12 it is notable that someinventors, myself among them, who taught the use of expanded metal as awater receiving area of a gutter guard, illustrated that the expandedmetal was positioned so that, what is known in the expanded metalindustry as the LWD: “long way of the diamond” is parallel to water flowoff of a roof structure. I taught, by illustration, this in U.S. Pat.No. 6,951,077, Hileman taught this in U.S. Pat. No. 4,592,174 (FIG. 5),and Jones taught this in U.S. Pat. No. 5,592,783 (FIG. 3). A productcurrently on the market: Leaf Solution®, invented by this applicant,employs expanded metal overlain my micro mesh and in this product theexpanded metal's diamond shaped openings are also positioned so thattheir LWD is parallel to water flow. Not every type of expanded metalemploys diamond shaped openings but the same changes in water directingproperties of expanded metal openings that occur when you re-position adiamond shaped expanded metal opening, in relation to oncoming waterflow, hold true when repositioning any geometrically shaped expandedmetal opening. For the purpose of this application, the term “LWO”:“Long way of the opening” will be used going forward.

Other prior art in the field that teaches the use of expanded metal as awater receiving area of a gutter guard illustrates the expanded metal ispositioned so that the LWO is perpendicular rather than parallel towater flow. Examples of this are found in U.S. Pat. No. 4,036,761 (FIG.1), U.S. Pat. No. 4,959,932 (FIG. 1).

In the LWO pattern (the openings being formed by 6 sidewall members)utilized in an embodiment of the present invention there are fourpossible positions the pattern may be positioned to in relation tooncoming water flow: these positions are shown in the attachmentaccompanying this Specification titled “Sidewall Positions” and will bedescribed in detail later in this application.

Referring now to Exhibit 1 “Sidewall Positions” and viewing fourpossible positions an LWO opening could be in while facing oncomingwater flow, which position, if overlain by screen, would be the mosteffective water-redirecting position of the expanded metal to use? Or,are each of the positions equally effective? Or, would NONE of them workvery well at capturing and redirecting water down into an underlyinggutter? Further teaching present within this application points readilyto the best answer but, can someone “skilled in the art” make thecorrect choice without reading my application any further and, instead,only draw on the teaching of prior art? As noted earlier: Prior Art'scomments on the matter counsel to ensure sidewall members are angledaway from water flow (I teach the opposite in the present invention).

Prior Art has taught to, whenever practical, NOT position side walls inthe manner the present invention teaches in any instance where the angleor bevel of sidewalls is mentioned.

An example of such Prior Art teaching is found in Mr. Ealer's2006/0230687 [0009]; “The strands and non-circular holes are sized andshaped to prevent leaves and debris from falling into a gutter”. Toachieve that purpose you would want to angle the sidewalls away from theroof, not toward the roof as I teach. Otherwise, pine needles andsmaller debris would be channeled, captured, and held within the airopening by sidewalls angled toward them as they come off of the roof.This is why LWO gutter guards employ sidewalls that are eitherperpendicular to or angle away from a roof's edge: doing so enables, asPrior Art teaches: sidewalls to act as a slide to deflect or encourageforward progression of debris.”

Products in the field that do exhibit a LWO pattern of expanded metaloverlain with screen are not installed at angles in line with roof pitchbut, instead, mostly flat. The manufacturers and installers are verylikely aware that such products fail at taking water when installedin-line with roof pitch. The experience and conventional wisdom of PriorArt manufacturers and those “skilled in the art” was that expanded metalgutter guards overlain with fine screen should not be angled with roofpitch. This is understandable because it is very likely that thosebefore me also grabbed a LWO pattern to experiment with and found it to“not work” if overlain by screen unless the product is mostly flatwithin a gutter. Why would this be the case?: When expanded metal LWO“sections” (typically 3 or 4 foot lengths with widths of 3 to 9 inches)are created for use as gutter guards they are stacked in a box and thentaken to other machines that perform secondary operations such asapplying screen overlayment or fastening members. The “sections” may bewithdrawn from the box in 1 position on one occasion and in an entirelydifferent position another time depending on who stacked the LWO“sections” and how they stacked them at the time. Until this presentteaching of the present invention, there have been no directions orreasons given for which position an LWO segment should be in when beingsubjected to secondary operations. Any old position would do.

I experimented with LWO positions with no conjectured results In mindjust to see what might be discovered. Unless, as was the case with me,someone thought to try flipping the particular segment of expanded metalI picked up upside down and then turn it 180 degrees it no effectivegutter guard (consisting of an LWO pattern overlain by screen) wouldhave ever been created by secondary operations. LWO patterns/overlain byscreen will always yield poor performance . . . at least in 3 out of 4LWO positions. I am not saying some folks don't manufacture LWOpatterned/overlain by screen gutter guards anyway, but I am saying thatsuch gutter guards don't work very well. Why then are they made? Well mybelief is that once I introduced “micro-mesh” gutter guards to themarketplace their success was astounding and scores of “copy cats” beganto appear that had the appearance of my original Leaffilter because theytoo employed micro-mesh or fine screen but very few come close toLeaffilter's performance. People buy gutter guards on wishes and hopesthat the sales pitch they heard is true but most of what is bought turnsout to be a major disappointment. But gutter guards continue to sell,especially a micro-mesh gutter guard, regardless of performance. Not allmicro mesh gutter guards are created equal.

My Leaffilter product (the first micro-mesh) is now the largest sellingdealer-installed product in the nation. It's largest dealer hits around$40 million per year. That is a record in our industry. That is the goodnews! The sad news (for me) is that I sold the company before ConsumerReports tested gutter guards and rated it Number One and I don't evenget a Christmas card from my old friends at Leaffilter anymore. But,that's ok, I done it before and with my latest gutter guard maybe I can“done it again” (If patent rules allowed the insertion of a “smileyface” I would post one here). I have tried to create gutter guards thatactually work and though I may not be a master of marketing I am, Ithink, very good at inventing gutter guards. Not because I am so smartbut because the Lord has helped me to discover the things I teach.

Consumer Reports recognized my technology as the best available. It is.Still, I, as the “Father of Micro-Mesh gutter guards” wasn't able toglean or confidently predict the “correct” position an LWO segmentshould be in from Prior Art or from intelligent conjecture: I just keptflipping and turning and bending sidewalls and observing and eventually“accidentally” discovered what is now taught in this application. Isn'tthat how most inventions occur?

The new art of the present invention teaches a new method or combinationof expanded metal with fine screen that offers an expandedmetal/overlain by screen gutter guard which allows copious amounts ofwater flow-through (through the screen down into the gutter) even whenthe new invention is installed at pitches as steep as 12/12. Prior Artteaching in 52/12 and products in the field cannot achieve that.

It is important to note that sidewalls of expanded metal openings arecreated by a punching die that creates sidewall members that have anarrow edge and a broader edge. Below are listed several identifiableelements or characteristics of expanded metal openings and the sidewallsthat perimeter and form them:

1. Relative length of one sidewall compared to others that are connectedand form perimetered opening 2. Degree of parallel or perpendicularposition of a sidewall length with regards to oncoming water flow 3.angle of bevel of a sidewall member toward or away from water flow widthof the top edge of a sidewall member in relation to width of the bottomedge of the member (“narrowness” of the edge). The more “knife-like” andless blunt an edge is, the better it will capture and redirect water. Ido not teach “narrowness” alone as much as I teach: “choose the narroweredge of the sidewall” to face oncoming water:4. A narrow edge (contacting the underside of a fine screen) thatcaptures and channels water down the sidewall to the somewhat broaderterminating edge (bottom edge) of the sidewall yields great waterchanneling effects. Reverse the position and water channeling isdiminished.—(New Art or new teaching not present in 52/12 to the best ofmy knowledge). Given these factors or elements: there are at least 4possible LWO patterns or sidewall positions that might face oncomingwater flow that are achievable in different combinations whenconsidering factors #3 and #4 listed above. Referring to the Attachment(Exhibit 1) entitled: “Sidewall Positions and Properties” there is shownfour possible positions of a six-sided sidewall membered LWO pattern inrelation to oncoming water flow, looking at the photos; your eyes arerepresentative of water flowing off a roof and toward the gutter guard:

Position 1: Sidewalls angled away from oncoming water flow with the topedge of the sidewalls contacting the underside of an overlying screenbeing broader than the sidewall's bottom edge. Also note the smallestsidewall member appears almost welded to and almost level with thelargest sidewall member.

Position 2: Sidewalls angled toward oncoming water flow with the topedge of the sidewall contacting the underside of an overlying screenbeing broader than the sidewall's bottom edge. Also note that theadjoining point of the smallest sidewall member with the longestsidewall member appears very broad and flat and the smallest sidewallmember appears slightly above the longer sidewall member.

Position 3: Sidewalls angled toward oncoming water flow with the topedge of the sidewall contacting the underside of an overlying screenbeing narrower than the sidewall's bottom edge. Also note that thelongest sidewall member is positioned slightly above the smallestsidewall member at their point of adjoining.

Position 4: Sidewalls angled away from oncoming water flow with the topedge of the sidewall contacting the underside of an overlying screenbeing narrower than the sidewall's bottom edge. Also note the longestsidewall member is positioned well above the smallest sidewall member.

On the surface, it might seem obvious to simply overlay one of the fourpossible expanded metal patterns with a screen and thereby achieve aviable gutter guard able to shed debris and redirect water downward intoan underlying gutter. But experimentation will show that it isn'tobvious to simply overly an expanded metal pattern with screen thinkinga viable gutter guard will be achieved. Absent an overlying screen, anyof the four positions will allow plenty of water into an underlyinggutter but when overlying screen is added significant differences amongthe LWO positions begin to show.One gutter guard presently on the market:Diamond Back Gutter Cover™ whose sales literature is shown in EXHIBIT 2in this application overlies an Expanded Metal LWO pattern with screenhowever: the product's literature seems to show sidewalls angled awayfrom water flow. One more example of a LWO pattern overlain by finescreen is a product on the market: Sentinel® Gutter Debris Shield whichis manufactured under U.S. Pat. No. 5,956,904 and whose product photo isshown in EXHIBIT 3. The Sentinel product shows that “broad edges”,rather than narrow edges of the sidewalls face upward and would be thefirst part of the expanded metal to contact water. In the above twoinstances: an LWO pattern with sidewalls angled away from oncoming waterflow off of a roof and overlain by fine screen and a LWO pattern whosebroad edges contact the underside of an overlying screen, waterflow-through is significantly inhibited in comparison to the presentinvention which positions sidewall members differently.A recent “screen over LWO expanded metal” entry in the gutter guardmarket is Ultra Klean Gutter Guard whose product photo is shown inEXHIBIT 4. As is seen in both Diamond Back and the Sentinel product, thelonger sidewalls present in the expanded metal patterns are notperpendicular to water flow as is the case with the present invention.Referring to FIG. 5 of this application, in the LWO pattern shown S3 andS6 are perpendicular to oncoming water flow off of a building's roof butare shorter rather than longer sidewalls in comparison to the remainingsidewalls: this incorrect sizing is what is found in the Sentinel,Diamond Back and Ultra Klean Gutter Guard products. The presentinvention teaches that S3 and S6 should be no shorter than the longerS1, S2, S4 or S5 sidewalls.

When I invented the Leaf Solution product (the first micro-mesh overexpanded metal gutter guard which preceded the above mentioned gutterguard products) I was unaware, at the time, that expanded metalpositioned in the manner I had chosen: LWO parallel to water flow,allowed a water overflow that could be significantly reduced if theexpanded metal was positioned so that two things occurred. First, thesidewalls of the expanded metal walls that make up a diamond shaped (orany shaped) expanded metal opening should be angled upward and towardoncoming water flow. That property was not and is not existent in theLeaf Solution product or the Sentinel or Diamond Back products. Second,the expanded metal should be positioned so that the LWO is perpendicularto oncoming water flow with at least one longer or longest sidewallbeing perpendicular to water flow. Improper size and angling andbeveling of expanded metal side walls and failure to ensure narrow,rather than broad edges, of expanded metal sidewalls are atop thesidewalls is in large part the reason for “less than could be achieved”water flow-through performance of expanded metal gutter guards overlainby screen: “less than could be achieved” in comparison to the teachingof the present invention.

I discovered by experimenting with the Leaf Solution product at RollFormer® Company in Chalfont Pa. that if I repositioned the productsunderlying support base (the expanded metal that supports overlyingmicro mesh) so that the LWO was parallel to oncoming water flow, as itis in some Prior Art, the Leaf Solution product directed or pulled a bitmore water downward through the overlying micromesh.

As stated earlier, other prior art had already taught, at least byillustration, positioning the LWO perpendicular to water flow. Though itmay exist in the language of a patent, I have found no specificationaddressing this advantage offered by positioning expanded metal openingsso that their LWO is perpendicular to water flow. I am guessing thatother manufacturers or inventors did as I did: took whatever expandedmetal was readily available and shaped it into a gutter guard withoutconsidering or noting the ability of “LWO perpendicular to water flow”products To redirect more water flow downward into an underlying raingutter that “LWO parallel to water flow” products.

However, what no other prior art has taught and no product presently onthe market, that I am aware of, employs is a gutter guard that utilizesexpanded metal openings in combination with overlying micromeshfiltration in which you would find that LWO expanded metal openings areboth perpendicular to oncoming water flow and whose majority of sidewallmembers are angled upward and toward oncoming water flow and whosesidewalls present their narrow edge, rather than their broader edge,toward oncoming water flow while ensuring the LWO pattern used positionslonger or the longest sidewall member perpendicular to oncoming waterflow. It is the narrow edge of sidewalls, present in anLWO-perpendicular-to-water-flow-opening, angled upward and towardoncoming water flow”, in combination with an overlying micro mesh orother filtering method art that this application presents as new art.

The new art of the present invention teaches a new method or combinationof expanded metal with fine screen that offers an expandedmetal/overlain by screen gutter guard which allows copious amounts ofwater flow-through (through the screen down into the gutter) even whenthe new invention is installed at pitches as steep as 12/12. Prior Artteaching in 52/12 and products in the field utilizing ExpandedMetal/overlain by micro-mesh or fine screen cannot achieve that.

However, as noted; only one of the four possible positions of a LWOpattern, if overlain by a fine screen will exhibit little, if any, waterrun off past a gutter if the expanded metal/fine screen combination isinstalled on a gutter in-line with a roof's pitch.

It is also important to note that in the event the sidewalls of a LWOpattern are angled either away from or toward water at angles greater(or less than) 45 degrees it is possible that none of the four positionswill achieve a gutter guard that allows significant water flow-throughif pitched with a roof. The reason for this is that, although a sidewallmay correctly present it's narrow edge on top of the sidewall andalthough the sidewall may be angled toward water flow: it may be angledtoo obtusely or too acutely.

There are simple “expanded metal only” (not overlain by micro-mesh orother filter) gutter guard products on the market whose expanded metalopenings are both LWO perpendicular to oncoming water flow and whosemajority of sidewall members angle upward toward water flow. But thereare none on the market or described or illustrated in prior art where itis found that these three properties exist: 1. The expanded metalopenings are LWO perpendicular to oncoming water flow 2. The majority ofthe sidewalls or the largest linear portion sidewall members of theexpanded metal openings are angled upward toward oncoming water flow;the top edge of sidewalls faces toward rather than away from oncomingwater flow. And: 3. The expanded metal as described in criteria one andtwo above is overlain by micromesh or other filtering membrane.

There is a range of angle that seems to best capture and redirectoncoming water flow.

Additionally, I am conjecturing (having not yet tested my conjecture)that there is an ideal ratio of narrow top edge to wider bottom edge ofa sidewall that best captures and redirects water downwards. I am fairlyconfident, before testing, that an “inverted pyramid” shaped sidewallwill not perform as well as having a narrower type and wider bottom edgeor a consistently narrow sidewall. This is just conjecture but as I amrushing to submit this application I will just let the statement bepresent on record untested.

Gutter Guard inventors (not “knock-off” or copy-cat artists but realinventors) are ever seeking to improve the water permeability of theirproducts, this new art, though easily achieved by repositioning of theunderlying expanded metal supporting structure, has not been obvious. Iremember the reaction of Bob Schultz, mechanical engineer and part ownerof Roll Former Corporation® who has designed many, if not the majorityof gutter guard roll forming machines on the market today. When I showedBob what the repositioning of expanded metal beneath a micro meshoverlay accomplished, he was speechless for a moment: the amount ofwater this new art redirects downward through itself over prior art isvery significant. Anytime I can teach Bob how to do something with agutter guard he didn't know how to do I feel like I am walking withengineering giants. The same holds true with Jim Zauderer of GlobalExpanded Metals who manufactured the first expanded metal gutter guard:Jim couldn't identify which of the four positions would work best orexplain why that would be the case, either, when we were discussing myprototype of the present invention. In fact, Jim stated something alongthe lines of: “Alex, (Edward) if we knew how you do what you did wewouldn't be having this discussion”. I have to smile when I write that,and be grateful to the Lord. Jim is a good guy and an honest guy whichisn't always the case in our industry.

I mention Jim and Bob because they are two of the most knowledgeable andrespected men today in the field of gutter guards and definitely qualifyas “experts in the field”. I know that even their expertise andexperience doesn't rise to the technical definition of “someone skilledin the art” but still thought the conversations were worth noting.

A product currently on the market today: Micro CS® offered by GutterHelmet®, whose product literature is included in this application,utilizes a micro mesh cloth overlying a supporting base of a planarsurface out of which arises multiple louvers: concaved semi-circles orhoods with open air faces that do face the oncoming flow of water. Thisart offers a feature: an angled element facing oncoming water flow justas the present invention offers but the difference between the two artsare significant both visually and also in the area of waterpermeability. Only a small segment of the “hoods” of the Micro CSproduct contact the under-surface of the cloth and not nearly as muchopen air space is provided in this art. The louvers or hoods arepositioned in linear rows, not in honey-combed fashion as the openingsin expanded metal are, and side by side comparisons illustrate that theMicro CS product redirects much less water through it than the new artdescribed in this application: it just has too much solid metal betweenopen-air-space openings with only one water directing plane arising outof and above an open air space rather than six; as an embodiment of thepresent invention teaches.

Prior Art Fascia Mounted Hanging Systems

The invention employs concepts related to and, in some instances,extrapolated from prior art disclosed in U.S. Pat. No. 7,104,012 toBayram, U.S. Pat. No. 7,730,672 to Knudson, U.S. Pat. No. 7,448,167 toBachman, U.S. Pat. No. 7,748,171 to Barnett, U.S. Pat. No. 7,740,755 toWilson and Rassor, U.S. Pat. No. 6,935,074 to Gramling U.S. Pat. No.7,752,811 to Pavlansky, and U.S. Pat. No. 7,658,036 to Banks.

Operation of an Embodiment

Referring to FIG. 29 and FIG. 34 a gutter mounting rail 31 will beattached to a fascia board utilizing screws 30. Referring to FIG. 34:double-rear-looped hangers 29 are inserted into a rain gutter 33. Therain gutter is then lifted into place and hung on the gutter mountingrail 31 that has been prefastened to a building's fascia board 32. This“free hanging” method of installing a rain gutter allows for lateralrepositioning of the rain gutter.

An embodiment of the invention: an insertable gutter guard filter 34, issecured to the rain gutter by inserting the rear portion 34 f of thegutter guard filter beneath a roof covering or shingles 35 and byensuring downward extending plane and engaging element 34 e ispositioned behind upward extending clip 29 c of gutter hanger 29. A topsolid plane 34 d of the invention will rest on the top front lip of therain gutter. To ensure little or no gap exists between plane 34 d andthe front top lip of the rain gutter, the invention's downward extendingplanes 34 b and/or 34 e may be bent upward and/or upward extending clip29 c of the gutter hanger may be bent downward.

Once installed, the invention serves as a debris blocking waterchanneling gutter guard in the following manner: rain 5 d will flow offof a roofing membrane 35 contacting a micro max sheer cloth (“sheercloth” as defined in paragraphs 2 and 3 under the heading SHEER CLOTHfound in the DESCRIPTION OF AN EMBODIMENT of this application). Theclose, but not too close, proximity of the threads within the sheer or“micro max” cloth allow the water coating and adhering to each thread tojoin in a single heavier column of water spanning the open air spacebetween them which encourages the water to “let go” and cease adheringto the threads and continuing forward water flow along the threads and,instead, drop downward. Were the threads too close or to far from oneanother, this column of water would not form. The water becomes moreattracted to the shared central column of water between the threads thanit is to the threads themselves and when the column of water is heavyenough it forms and becomes it's own downward (away from the horizontalplane of the cloth) flow path.

Additionally, any water that does cling to the underside of the sheercloth is interdicted by the angled and upward extending sidewalls 2 a ofthe expanded metal openings: the water forms a greater adhesive bondwith the angled sidewalls than to the cloth and begins to channel downthe sidewalls and drop into an underlying gutter. The sidewalls areangled toward water flow and their top edge is narrower than or of thesame width as their bottom edge. When the angle of the sidewalls is notacute enough (less than 20 degrees) or oblique, or too acute (greaterthan 70 degrees) or the sidewalls are angled away from water flow; lesswater releases from the cloth. The 20 to 70 degree angle offers both theunderside and top side of the expanded metal sidewalls as water flowpaths to oncoming water that the water will more readily adhere to thanthe sheer cloth (or any other similar filtering method) it previouslyadhered to. When the angle is not quite acute enough, or at 90 degreesor greater, the water tends to “see” or be attracted to only one side ofan expanded metal sidewall because only one side is readily orimmediately available for contact by water. For example: if the sidewallis at a 90 degree angle, oncoming water “sees” and readily contacts thetop narrow plane of the sidewall and only has to dip slightly to adhereto the downward extending face of the sidewall facing it, but thebackside of the sidewall which is “hidden” from the view of the oncomingwater does not present such a readily available or alternative waterflow path so any water not captured an redirected downward by the topand front side of the sidewall tends to remain clinging to the sheercloth and keep flowing forward. Oblique or slightly acute angles alsoreadily offer one side, rather than two sides, of a sidewall to oncomingwater.

It has also been noted in testing that sidewalls that have more length:a deeper extension downward of the sidewall, channel more water bydiscouraging less forward underflow of water. Shallow depth sidewallsmake it more probable that water will “loop” around the bottom of thesidewalls and back up to the underside of cloth and keep on forwardflowing.

Any water that would not be redirected downward through the waterreceiving area of sheer cloth (or other filtering membrane) thatoverlies expanded metal with properly angled sidewalls will beinterdicted and directed downward by downward extending inseam or plane29. Plane 27 is solid or mostly solid and further directs water thatcontacts it downward and away from the front lip of the gutter. Verticalcolumns of water tend to form between plane 27 and the overlying waterreceiving area of the invention that provide more attractive water flowpaths to water than are present when water simply free falls downthrough the water receiving area.

Side by side testing of the present invention which employs sidewallsangled as described has shown it to be demonstrably more effective atcapturing and redirecting water downward and at self-cleaning itself ofshingle or other oil that may deposit on the invention.

Any water receiving area of any alternative embodiment of the presentinvention illustrated or described within this application will operateby the same principles described above in this section: “OPERATION OFTHE MAIN EMBODIMENT”. Alternative embodiments shown are mostlystructural reconfigurations that may make the present invention morereadily adaptable to certain circumstances present at installationsites: certain alternative embodiments may allow for easier installationor more water capture and redirection in certain environments. Forexample: FIG. 32 illustrates an embodiment of the invention thatutilizes a hanging assembly attached to the fascia board of a buildingstructure. This embodiment may be necessary when California Slate styleroof coverings or poured rubber roof coatings make it impossible toinsert the back edge of an embodiment beneath the roof covering forsecuring as the Main Embodiment teaches in FIG. 34.

SUMMARY OF THE INVENTION

With this invention a gutter guard system is provided for a gutter whichincludes an expanded metal water receiving and water re-directing areaoverlain by a filtering membrane. The expanded metal is expanded “TheLong Way of the Diamond” in relation to the expanded metal's longestedge and in relation to a building's fascia board and oncoming waterflow off of a building's roof: the openings defined by sidewallsexistent in the expanded metal have a length greater than width and thelength is parallel to oncoming water flow.

At least two sidewalls of any expanded metal opening angle upward andinto oncoming water flow. The sidewalls have top edges that are narrowerthan or equal to the width of the bottom edges of the sidewall. Theexpanded metal opening is then overlain by a filtering membrane.

Positioning the expanded metal “Long Way of the Diamond” in relation tooncoming water flow and ensuring at least two of the expanded metalopenings' sidewall members are angled upward and forward into waterflow, rather than parallel or nearly parallel to it as well as ensuringnarrow edges of the sidewalls face oncoming water flow creates strongdownward flowing water flow paths in conjunction with overlying micromesh or other filtering membrane materials.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view of an expanded metal gutter guard employing an expandedmetal pattern composed of openings “expanded vertically to the longside”

FIG. 1 a is a view of an expanded metal opening “expanded vertically tothe long side”, also termed: “short way of the diamond”

FIG. 1 b is an exploded view of a segment of an expanded metal gutterguard employing an expanded metal pattern composed of openings “expandedvertically to the long side”

FIG. 2 is a view of an embodiment of the invention: an expanded metalgutter guard employing an expanded metal pattern composed of openings“expanded horizontally to the long side”

FIG. 2 a is a view of an expanded metal opening “expanded horizontallyto the long side”, also termed “long way of the diamond”

FIG. 2 b is an exploded view of a segment of an expanded metal gutterguard employing an expanded metal pattern “expanded horizontally to thelong side”

FIG. 3 is a view of an expanded metal opening “expanded vertically tothe long side” illustrating side wall components

FIG. 3 a is a view representative of angles of tilt and water flow pathsthat exist in sidewall members of an expanded metal opening “expandedvertically to the long side”

FIG. 3 b is a view of an expanded metal opening “expanded vertically tothe long side” showing water flow paths along it's top surface

FIG. 3 c is a view of micro mesh filtration cloth

FIG. 4 is a view of an expanded metal opening “expanded horizontally tothe long side” illustrating top and bottom surfaces existent in eachside wall member

FIG. 4 a is a view of side wall members of an expanded metal opening“expanded horizontally to the long side” illustrating water flow paths

FIG. 4 b is a view of an expanded metal opening “expanded horizontallyto the long side” illustrating water flow path patterns that initiate onthe top surface of side wall members of the expanded metal opening

FIG. 4 c is a view of micro mesh filtration cloth

FIG. 5 is a view of an expanded metal opening “expanded horizontally tothe long side” illustrating height and width and separated individualside wall members of the expanded metal opening

FIG. 5 a is a view of an isolated side wall member of an expanded metalopening “expanded horizontally to the long side” illustrating angles oftilt and bevel existent in itself and associated side wall members.

FIG. 6 is a view of an expanded metal opening “expanded horizontally tothe long side

FIG. 6 a is a view of a side wall member of an expanded metal opening“expanded horizontally to the long side in a corrugated embodiment

FIG. 7 is a view of an embodiment of the invention overlain by micromesh filtration cloth

FIG. 8 is a view of an embodiment of an expanded metal opening “expandedhorizontally to the long side” with a center member

FIG. 9 is a view of micro screen or cloth with warp and weft threadsapproximately equi-distant from each other in all directions

FIG. 10 is a view of micro screen or cloth with weft threads spaced moreclosely to one another than warp threads

FIG. 11 is a view of a twisted or “cork screwed” thread

FIG. 12 is a view of a metallic thread micro screen

FIG. 13 is a view of a metallic thread micro screen with rectangularpatterns depressed or embossed into the cloth

FIG. 14 is a profiled and top perspective view of a rectangular shapedwell that has been depressed or embossed into the cloth

FIG. 15 is a view of a gutter guard employing a water receiving areacomposed of a metallic thread micro screen with various shaped patternsrecessed or depressed downward into the metallic cloth

FIG. 16 is a view of a recessed or downward embossed heart shapeillustrating water flow patterns

FIG. 17 is a view of a recessed or downward embossed rectangular “bowtie” shape illustrating water flow patterns

FIG. 18 is a view of the invention affixed to a rain gutter

FIG. 19 is a view of a metallic thread micro screen or cloth with wordphrases depressed or embossed downward into it's top surface

FIG. 20 is a view of a metallic thread micro screen or cloth withdepressed or recessed shapes (embossed downward) out of which arises anupward embossed plane or shape and which incorporates a downwardextending inseam

FIG. 21 is a view of larger diameter threads

FIG. 22 is a view of smaller diameter threads

FIG. 23 is a view of smaller diameter threads more closely spaced

FIG. 24 is a top view of expanded metal that has been expandedhorizontally to the long side into which has been embossed or depressedwells or channels

FIG. 25 is a top view of expanded metal that has been expandedhorizontally to the long side into which has been embossed or depressedwells or channels and which is covered with a filtration membrane

FIG. 26 is a view of an embodiment of the present invention illustratinga reverse curved drip edge element with a gutter guard receivingchannel, with gutter guard inserted

FIG. 27 is a view of an embodiment of the present invention illustratinga reverse curved drip edge element with a rear engaging sleeve

FIG. 28 is a view of a gutter hangar exhibiting two rear clip elements

FIG. 29 is a view of a dual channeled rail that serves as a gutter guardand gutter hanging assembly

FIG. 30 is a view of an embodiment of the present invention attached tothe fascia board of a building

FIG. 31 is a view of a filtration element that employs solid lower waterdirecting planes

FIG. 32 is a view of an embodiment of the present invention attached toa building structure and illustrating water flow paths

FIG. 33 is a view of an embodiment of the present invention in which thegutter guard will flex upward to contact the underside of a sub-roof.

FIG. 34 is a view of an embodiment of the present invention installed ina rain gutter in which the gutter guard will flex upward to contact theunderside of a sub-roof.

FIG. 35 is a black and white photo of an expanded metal portion of thepresent invention

FIG. 36 is a view of an expanded metal pattern representative of any LWOpattern having more than 6 sidewalls.

DESCRIPTION OF AN EMBODIMENT

Referring to FIG. 2 b this embodiment teaches the utilization ofexpanded metal that employs openings whose longest measured air space 2a 1 is longitudinally parallel to the longest edge 1 b of the sheet orroll of the expanded metal they exist within and whose sidewall membersare angled upward from the original plane of metal they have beencreated from. This allows for the expanded metal to be placed over arain gutter in such a manner that each sidewall member, or the majorityof sidewall members, of each punched opening is facing the oncoming flowof water off of a roof structure. Expanded metal exists as both“flattened” in which the sidewall members are flat; not angled, and as“standard” or “angled side wall members”. The present invention employs“Standard” expanded metal that is then coupled with a “sheer” filteringoverlay for the purpose of preventing debris entrance into a gutterwhile redirecting water flow into a rain gutter.

Expanded Metal

Referring to FIG. 1 b presently, the most common method in which metalis expanded is to employ a punching process that results in “verticalexpansion to the long side”. This industry term describes the positionalrelationship of the individual expanded openings in relation to thehorizontal length of a coiled roll of expanded metal: Referring to (FIG.1 b) 2 a 1 and 1 b, “vertical expansion to the long side”, also termed:“short way of the diamond” indicates that an elongated expanded metalopening's longest measured air opening is perpendicular to the longestedge of the expanded metal sheet or roll.

Referring to FIGS. 3 and 3 b when expanded metal that has been expandedto “the short side of the diamond”, also referred to as “SWD” isutilized as a gutter guard device, the punching and tearing dies arepositioned in such a way that they create sidewalls for the expandedmetal openings that present a mostly flat top surface which parallelswater flowing off of a roof structure. When forward flowing watercontacts this type of “short way of the diamond” pattern it tends tostay on the top surface of the diamond opening's sidewall members andflow over and past the underling gutter. This pattern of water flow pastan underlying gutter, rather than down into it, is exacerbated whenfiltering methods overly expanded metal employing “short way of thediamond” openings which, until the present invention, is to the best ofmy knowledge, the only known screen-over-expanded metal type of gutterguard disclosed in Prior Art or offered for sale. Sidewalls notpositioned more perpendicular to water flow and not angled upward toface oncoming water flow in such a manner that the top most edge of eachside member “slices” through the oncoming water flow have proven to beonly partially effective at capturing forward flowing water andredirecting it downward.

The “horizontal expansion of the long side” also known as “Long Way ofthe Diamond” or; “LWD” method of expanded metal punching is employed bysome manufacturers of expanded metal: referring to FIG. 1 b this type ofmetal expansion produces horizontal lengths of expanded metal that havethe longer side of their expanded metal openings 2 a 1 run parallel tothe length of an expanded metal roll of material, allows a previouslyundiscovered or non-disclosed opportunity for a length of, referring to(FIG. 7) 2 a, such expanded metal to be coupled with a filteringmembrane and positioned so that every sidewall of the expanded metalopening presents top surfaces of the sidewalls that are mostlyperpendicular to water flow and are angled upward and into oncomingwater flow as disclosed in FIG. 4 a allowing for greater capture andredirection of oncoming water flow.

However, simply utilizing “LWD” patterned expanded metal (the expandedmetal openings would have their longest dimension parallel to a roofline or fascia board) as a gutter guard or water receiving area forwater coming off of a roof does not result in much, if any improvementin water redirection downward. I say this because whenever “LWD”openings are created they are created with angled sidewalls that may bepointed toward or away from oncoming water flow and the top edge andbottom edge of the sidewall may be either narrow and “sharp” or broadand flat. The present invention teaches that the LWD sidewalls must beplaced not solely in a position parallel to water flow and then overlainby micromesh; the present invention additionally teaches that two ormore of the sidewalls composing the diamond openings must be angledupwards toward oncoming water flow off of a roof and that it ispreferable if the top edge angling toward water fall is also a narrowerrather than broader width.

Referring to the drawings wherein like reference numerals represent likeparts throughout the various figures, reference numeral 2 (FIG. 2 a)discloses a gutter guard employing 2 a a pattern of expanded metalopenings 2 a 1 (FIG. 2 a) formed with horizontal widths greater than orequal to their vertical heights.

Referring to FIG. 5 it is shown that the expanded opening 4 is composedof six sidewalls s1,s2,s3,s4,s5, and s6. Referring to FIG. 5 a sidewalls1, is shown as possessing an angle of tilt, from it's top surface 4 ato it's bottom surface 4 b that may vary from 1 degree to 45 degrees.The top edges: 4 a, 4 d, 4 f, 4 h, 4 i, and 4 k have a width equal to orless than their corresponding bottom edges: 4 b, 4 c, 4 e, 4 g, 4 j, and4L.

This angle is in reference to the horizontal top surface of the flatsheet of metal or plastic from which it was formed. This same angle oftilt exists in sidewalls s2,s3,s4,s5,s6.

Referring to FIGS. 4 and 4 a it is shown that sidewallss1,s2,s3,s4,s5,s6, each are beveled and angled in a direction in whichtheir top surface is angled toward and face oncoming 5 water flow from abuilding's roof structure. Prior art and marketed product have not notedor employed this positioning of each sidewall member of an expandedmetal opening for use as a gutter guard.

Utilizing expanded metal that has been “horizontally expanded to thelong side” allows the expanded metal pattern (FIG. 2) 2 a to capture andredirect water downward FIG. 4 a in far greater volume than can beachieved by prior expanded metal patterns which offer only two sidewallmembers (FIG. 3 a) cs1,cs4 or, in some cases, two small thread juncturesthat capture and redirect water in similar fashion. What is termed“vertical expansion of the long side” has been the expanded metalpattern employed by gutter guard products that utilize a fine, but notsheer, micro screen overlying expanded metal. Examples of this are foundin the currently marketed Leaf Solution® and IG2® gutter guard products.This type of pattern, as noted earlier in this disclosure, does notallow for all sidewalls to be optimally angled for water capture andredirection. Referring again to FIG. 3 a it is illustrated thatsidewalls cs2,cs3,cs5, and cs6 possess top surfaces 3 c,3 e,3 i,3 k thatare tilted away from oncoming water flow and possess less ability toreadily capture and redirect water downward. When water contacting anexpanded metal gutter guard that has “vertical expansion of the shortside” it tends to flow along the top surfaces of the expanded metal topsurface of each expanded metal opening as illustrated in (FIG. 3 b) 3,rather than to flow down each sidewall and into an underlying raingutter.

Overlying such vertically expanded opening with micro mesh (FIG. 3 c) 3m or other filtration members seems to exacerbate this phenomenon, mostlikely due to strong water adhesion bonds created at the points ofcontact between the micro mesh causing water to cling to both the bottomof the micromesh and top surface of the expanded metal openings andcontinue flowing forward to the front lip of a gutter rather thandownward into it. I first noted this in my U.S. Pat. No. 6,951,077(Claim 1, Par 18 lines 67 and Par 10 lines 1,2,3). in which I taught thebreaking of the forward flow of water by employing downward inseamscomprised of micro mesh cloth and expanded metal extending downward intoa rain gutter. A similar breaking of the forward flow of water andredirection of it downward is achieved by the angled positioning of thesidewalls of expanded metal openings upward and into oncoming waterflow. The more recent and limited “horizontal expansion of the longside” employed by some manufacturers of expanded metal allows, but doesnot ensure, a previously unknown or non-disclosed opportunity for everysidewall of the expanded metal opening to be angled so that the topsurfaces of the sidewalls are angled upward and into oncoming water flowas disclosed in (FIG. 4 a) allowing for greater capture and redirectionof oncoming water flow.

There is one known gutter guard company recently formed and doingbusiness as Diamondback™, that does utilize metal horizontally expandedto the long side, or LWD, overlain with a fine, but not sheer, stainlesssteel mesh screen but a critical flaw in the product that inhibits itfrom redirecting water flow as effectively as the present invention isthat the majority of sidewalls of the LWD openings are angled away from,not toward oncoming water flow. I point to this as a “critical flaw” orcritical difference between the product and the present inventionbecause of a readily demonstrated ability of the present invention'smuch greater Ability to capture and redirect forward flowing waterdownward due to the present invention's unique positioning of thesidewalls of a LWD pattern: ie; forward into oncoming water flow. waterthan the Diamondback gutter guard. Diamond back advertising alsodescribes the mesh as “having openings not too small, not too large” theopenings being 2/100 inch. This type of larger diameter thread mesh withcomparatively (to sheer micro mesh employed by the present invention)much larger air space openings allows pine needle tips and quite a bitof other small organic debris as well as shingle grit to pass throughthe mesh and into the gutter and does not exhibit the capabilities andimprovements existent within the present invention that are describedwithin this specification and have been shown to materialize only withthe utilization of what is described in this specification as “sheer”micro screen or micro mesh or micro cloth.

In prototype, overlying expanded metal openings that have been“horizontally expanded to the long side” (FIG. 4 b, 4 c) 4,3 m with“sheer” micro mesh or micro screen (cloths or screens with thread countsof at least 80 threads per inch and thread diameters smaller thanthreads commonly manufactured and utilized for a particular mesh/inchcount) or other sheer filtration medium provides the shedding of evenmicro debris: debris as small as 50 microns; dependent on threads perinch of the micromesh, while simultaneously capturing and redirectingwater downward through the screen and down the sidewalls (FIG. 4 b) 4 ofexpanded metal openings into an underlying gutter. Testing has shownthat this combination of sheer micro screen overlying this type ofunderlying skeletal structure captures as much, or more forward flowingwater as any 5 inch or 6 inch rain gutter can intake withoutoverflowing. Equally, and perhaps more importantly, this combination ofsheer micro cloth or micro screen overlying expanded metal expanded tothe “long way of the diamond” exhibits an ability to more quickly cleanitself of waterproofing oil elements than any known gutter preclusionmethod including: reverse curved, screened, louvered, perforated,screens and fine screens and micromesh overlying other underlyingskeletal structures, and combinations of such as are currently marketedtoday. I have tested the present invention's ability to self cleanitself of oil deposits against all manner of gutter guard devicesmarketed today, including the Leaffilter® and Gutter Glove® micromeshsystems (chosen by Consumer Reports® in a 2010 fall issue as topperforming in the DIY and Dealer installed categories . . . Leaffilterbeing my invention) as well as Gutter Helmet's® CS product and othermajor brands and technologies and am able to demonstrate that thepresent invention performs significantly better. It almostinstantaneously cleans itself of heavy and other oils exhibiting littleto no sign of water-proofing and water run-off exhibited by othermethods. Oil leaching out of roofing shingles and organic debris is amain, if not primary, cause of most gutter guard failure in the field:they become water-proof and tend to overshoot water past a rain gutterrather than down into a rain gutter.

As noted earlier: a product currently marketed as Leaf Solution® employsa micro mesh but not a sheer micro-mesh screen overlying an expandedmetal pattern employing openings expanded “the short way of the diamond”or SWD and it has been shown to have far less ability to capture andredirect water downward into an underlying gutter than prototypes of thepresent invention. Leaf Solution employs many elements of my U.S. Pat.No. 6,951,077 which teaches a filter method overlying a supportingskeleton of expanded metal that employs downward extending inseams. Atthe time I invented Leaf Solution, to the best of my knowledge; neitherI nor anyone else had yet discovered or tested combining micro-mesh orfiltering methods with expanded metal expanded “the long way of thediamond.” The Leaf Solution product, which employs a “short way of thediamond” pattern tested against the present invention, which employs a“long way of the diamond” pattern offers a convincing demonstration ofthe “long way of the diamond's” greater ability to redirect water flowdownward and self clean of oil, provided the sidewalls of the LWD methodare angled upward and toward oncoming water flow.

“Long way of the diamond” patterned gutter guard devices with nooverlying filtering membrane have been offered in the past and so have“short way of the diamond” patterned gutter guards. Both patterns; “longway” and “short way” of the diamond take equal amounts of water inmedium or heavy rains when not overlain by a filtering method. In lightrains, SWD gutter guards should tend to track more water forward ratherthan downward but once water volume reaches a certain point, enoughstrong downward flow paths off of the sidewalls into the rain gutter areestablished and SWD gutter guards perform pretty much the same as LWDgutter guards. However, a “long way of the diamond” patterned gutterguard overlain by a sheer micro-screen filtering method has never beendisclosed in Prior Art Applications and never offered for sale ormarketed to the best of my knowledge. I don't believe anyone knew of thesignificant difference such a pattern choice offers when in combinationwith an overlying filtering method: When I first tested the combinationI was greatly surprised at how much more water the sidewalls of thediamonds (overlain by micro-mesh) were able to capture and redirectdownward into an underlying gutter compared to gutter guards, such as myLeaf Solution invention, that employed a “short way of the diamond”underlying skeleton overlain by micro-mesh or other filtering membranes.

Without being overlain by micro-mesh or screen, expanded metal gutterguards show no difference in their ability to receive water off of aroof and redirect it's forward flow downward into an underlying raingutter. In fact, “long way of the diamond” gutter guards are moresubject to trapping and holding debris than “short way of the diamond”gutter guards because the “LWD”

Greater depths or downward extending vertical lengths (FIG. 4) 4 a-4 b,4 c-4 d, etc. of the sidewalls has been shown to capture heavier flowsof water.

Vertical height of the sidewall can't be made too long because moresurface area gathers more oil and pollen deposits that must be cleanedby down flowing water. Vertical height of the sidewall can't be made tooshort because an underflow of water will occur in which water will sheeton the underside of the micro screen and shallow expanded metal andcling to both their undersides and flow forward. The preferreddimensions of expanded metal openings that have been “horizontallyexpanded to the long side” are ones in which the horizontal width (FIG.5) 4 n is equal to or less than 15 mm and the vertical height (FIG. 5) 4o is greater than 0.9 mm and less than or equal to 8 mm. Though that istrue, it isn't my intention that the present invention be limited toemploying sidewalls with such dimensions or that the scope of this newteaching be viewed as excluding any sidewall elements outside of thosedimensions.

Referring to (FIG. 7) 2, a simple manufacture-to-market embodiment ofthe invention can be achieved by banding lengths of standard expandedmetal that has been “horizontally expanded to the long side” andoverlying sheer micro mesh with metal sleeves 1 b,1 c commonly employedby marketed gutter guards. “Horizontally expanded to the long side”openings as small as 5 mm or 2/10 inch wide can currently be achieved;such small openings serving as a somewhat effective gutter guard withoutthe overlayment of micro screen however, referring to (FIG. 7),overlying the “horizontally expanded to the long side” pattern 2 a withsheer micro mesh 3 m, then banding 1 b,1 c, will achieve a veryeffective and very inexpensively manufactured gutter guard able to shedsmall debris and capture and redirect significant amounts of rain waterinto an underlying rain gutter.

Another Embodiment

Referring to (FIG. 6,6 a) it is illustrated that sidewalls such as s4composing the expanded metal opening may be corrugated 4 m.

Another Embodiment

Referring to (FIG. 8) it is illustrated that center members 4 p: alsoshown as s7, may be added to provide more surface area for water tocontact. These members would also present top surfaces angled towardoncoming water flow.

Embodiment of an LWO Pattern

Referring to FIG. 36 there is illustrated an embodiment of an alternateexpanded metal pattern which is formed by 8 sidewall members: S1-S8.FIG. 36 is intended to be representative of any LWO opening having 5 ormore sidewall members. FIG. 36 illustrates sidewall elements that shouldbe present in an LWO pattern to achieve ideal water redirection; some ofthe most vital being:

1. The pattern should be formed of more than 4 sidewall members.2. At least two sidewall members (in the pattern shown in FIG. 36 themembers being S1 and S5) should be parallel or nearly parallel to thelength of the gutter guard or, stated differently: perpendicular tooncoming water flow OWF off of a roof.3. At least one of the two sidewall members (S1 and S5) that areperpendicular to oncoming water flow OWF should be as long as any othersidewall member present in the LWO pattern or, preferably: the longestsidewall member of the LWO pattern as S5 is in the pattern shown.4. The longest sidewall member, that is perpendicular to water flow,should “stack” atop or be in line with, not beneath, the sidewall memberimmediately behind it (in FIG. 36 this is shown with S5 stacking atopS1).5. Each of the sidewall members present a narrow and/or narrowest topedge angled toward on-coming water flow.FIG. 35 is a black and white photo with illustrator outlines of anexpanded metal portion of the present invention currently marketed asKlean Gutter gutter guard.

Another Embodiment Non Uniform Warp and Weft

Referring to (FIG. 9) 3 m there is illustrated a screen or cloth inwhich the warp threads 3 mwarp of a micro-mesh cloth and the 3 mweftthreads are spaced equi-distant or nearly equidistant from each other.

Referring to FIG. 10 Testing has shown that when the 3 mweft threads arespaced more closely than the 3 mwarp threads, creating more oblong orrectangular shaped air openings in the cloth, more water is captured andredirected downward by such a constructed cloth if the longer side ofthe rectangular opening is positioned perpendicular to oncoming waterflow, than is captured and redirected downward by cloth employing warpand weft threading that is approximately equidistant in all directionscreating somewhat uniformly sized and shaped air openings between warpand weft threads. This present invention may employ either: cloth ofuniform, or non uniform, warp and weft since both types of woven orknitted micro cloth materials prove very effective at channeling andredirecting water when employed as taught in this specification. Nonuniform warp and weft however is preferred but cost and availability mayencourage the utilization of more uniformed warp and weft cloth.

Warp knitted cloth has so far proven to be the most effective at watercapture and redirection, when employed as taught in my earlier patentsand in this specification, but is not, to date, a type of weave that canbe achieved in metallic threaded cloths.

When employing metallic threaded cloth; non uniform warp and weftscreens or cloths overlying standard expanded metal that has beenexpanded “the long way of the diamond” allows the present invention tocapture the greatest amount of oncoming rainwater flowing toward it thanfiltration cloths and micro screens utilizing more uniform warp and weftconstruction which are now commonly employed by gutter guard devicesavailable in the market place today. However, whether using uniform ornon-uniform warp and weft, ensuring the mesh or screen is sheer byutilizing small diameter threads and achieving at least 35% open airspace will enable the sheer cloth to counter-intuitively become verywater permeable even when the cloth is held at an angle while receivingon-coming water. Typically, non sheer multi threaded cloths of more than80 threads per inch will shed water much like a tent cloth does whenheld at an angle, sheer cloth much more readily directs the waterdownward through itself although it may appear solid.

Referring to FIG. 11 it is noted that the warp and weft threadsthemselves may be twisted or “cork screwed” which offers furtherresistance to the forward flow of oncoming water and enables cloth orscreens employing such twisted or “cork screwed” threads to redirectwater more effectively into downward flow with water more likely torelease from the bottom of the thread and drop downward.

Another Embodiment Embossed Shapes

Referring to FIG. 12 3 m there is illustrated a metallic thread microscreen or filtration membrane exhibiting a thread count of 80 threadsper inch or greater. This number, or a greater number of threads perinch, produce a micro screen or micro mesh that is cloth-like inappearance. Referring to FIGS. 13 and 14: when the threads of such amicro screen or mesh 3 m are of a sufficient hardness, recessed ordepressed patterns rd may be embossed downward into the 3 mts topsurface of the cloth. In this embodiment, the micro screen may functionunilaterally as a gutter protection method without the necessity of anunderlying support skeleton of expanded metal or of any other materialof configuration contacting the underside of the micro screen.Downwardly embossed shapes or downwardly extending inseams Referring toFIG. 21 have been observed to capture the forward flow of water, thatnormally occurs though a micro screen tilted at an angle, and redirectit downward into an underlying gutter. If the cloth is of sufficientstiffness it may serve, unilaterally when embodied as described, as agutter protection device in and of itself in areas void of heavy snowload. In regions where snow or other weight commonly occurs on roof andgutter structures an expanded metal and micro screen combination may bepreferred due to the greater structural integrity offered by thecombination.

Referring to (FIG. 16) 5 water flow paths are illustrated reaching theouter edge of a heart shape that has been recessed or depresseddownward. As is illustrated; when shapes are depressed downward intometallic thread micro screen or cloth water is far more likely to reachthe outer edge of the shapes and flow downward into them, rather thanaround them; as it does when it reaches the outer edge of perforationsor shaped perforations that have been punched through a solid metalplane. The reason water is more likely to reach the outer edge of suchrecesses and flow downward is due to the fact that the water is not onlyflowing across the tops of closely spaced cylinders that form the outeredges of the recessed shapes, it is also slowly around the outersurfaces of the soldiers downward. Water flowing only along the top of asolid plane tends to flow around rather than downward into a punchedhole or depression; at least to a greater extent than when water flowson and through a micro screen until it reaches a depressed or recessedshape. A somewhat related example of this tendency of water to beredirected to a greater extent by cylindrical paths is the employment inJapan and Asian nations of water directing chains at the end of theroofline rather than rain gutters.

Referring to (FIG. 16) 6,7, note that the left 6 and right 7 lowermostareas of the heart shape present a downward extending area ideal forredirecting water 5 a downward into the recessed area.

Referring to (FIG. 17) 5, 5 b, 8, 9, is again illustrated that waterflow paths 5 and 5 b tend to channel downward from the cylindricalthreads of the micro screen into top heads side edges of the recessedarea. My personal testing indicates that the amount of water flowingdownward from a planar surface when compared to water flowing downwardinto depressions made in metallic thread micro screens can only beequaled utilizing solid planar surfaces when they employ downward orupward extending louvers. Tapered punches sometimes employed by gutterguard devices also tend to direct water down more rest and that a“straight through punch” but still not as effective in as depressionsrecessed shapes made in metallic thread micro screens.

Referring to (FIGS. 18 and 19) 9,10,11,12,13,14 various shapes are shownrepresentative of the types of patterns that may be embossed recessedinto metallic thread micro screen cloths. 9: heart shape, 10: pawprints, 11: bowtie, 12: polygon, 13: a word phrase; “ALEX RULES”, 14: aword phrase; “KAREN RULES”. Testing has shown that shapes which employeecurved sidewalls such as a heart shape 9 more inwardly extendingsidewalls such as a bowtie shape 11 are effective and redirecting waterflow into and down side wall area. Decorative shapes such as animaltracks, trees, or other shapes may be employed for functional and/or formarketing or other purposes.

Another Embodiment Islands

Referring to (FIG. 20) 15,16,17,18, a metallic thread micro screen clothis shown employing a 18 continuous recessed shape out of which arises anupward extending shape 17 that further serves, referring to, referringto (FIG. 21) 17, 18, capture and redirect forward flowing water 5downward. Referring to (FIGS. 20 and 21) 15, 16, it is illustrated thatthe recessed shapes with their upraised planes may exist as smallersegmented units.

Intrinsic Ability to Capture and Redirect Forward Flowing Water

However, unlike previously tested fine and micro screens and cloths thatrequire a point of contact by a downward extending object on theirunderside to break the forward flow or sheeting of water, the unusuallysheer 120 mesh that employed 0.056 and 0.057 diameter warp and fillthreads, respectively, exhibited very little forward channeling of waterwhen the sheer mesh cloth is tilted at angles. This is an importantdiscovery because most gutter guards are tilted at angles more in linewith roof pitch to facilitate the falling away of leaves and otherdebris: Any micro screen or cloth that possessed an intrinsic,unilateral-non-assisted-by-other structures, capability of breakingforward water flow while screening fine debris would enhance any priorart method's ability to capture forward flowing water and redirect itdownward if such prior art employed fine or other filtering screens orcloths. The reason it would enhance is that the more easily and readilywater is directed downward, the less opportunity there is for pollutantsin the water to settle on screen and underlying surfaces and, foralready deposited organic oil or scum accumulations present from pineneedles and other debris, the more readily such pre-water flow existentpollutants will be cleaned and washed off of the screen and underlyingsurfaces.

For the purpose of this specification the term “sheer” will mean anycloth or micro screen composed of no fewer than 80 threads per inch,such threads exhibiting diameters At least 15% smaller than commonlyused thread diameters used and published in catalog offerings bycompanies that manufacture micro screen or cloth products. As anexample, most steel wire cloth manufacturers publish available threaddiameters of approximately 0.08 mm for their manufacture of 120 meshwire cloth. However, the “sheer” cloth I requested and tested, and notcommonly offered, is composed of threads with diameters of 0.056 and0.057 Which are approximately 30% smaller than the standard 0.08 mmthread found in 120 mesh stainless steel micro screen.

Intrinsic Ability to Shed Oil

Of any micro screen cloth I've ever tested over the years, none has evershed oil as this “sheer cloth” embodiment does. Pouring car oil or otheroils on the cloth have almost no effect on it's ability to take waterfrom it's top surface and direct it downward. Water almostinstantaneously pushes through the oil and drops down through the clotheven when the cloth is tilted at angles. The “pour oil on it” test is avery good indicator of how well a product will or will not avoid waterproofing in the field from leached shingle oil and other oil basedpollutants.

Referring to (FIG. 21 and FIG. 22) there is illustrated a representationof a 3 mt thread such as would be commonly employed in a micro screencloth comprised of 120 threads per inch with an existent D threaddiameter of 0.08 mm. There is also illustrated a representation of a 3mst thread with an existent D thread diameter of 0.057. Both sets ofthreads; the normal diameter and smaller diameter threads, are spaced 5sp equally apart. As is shown, the larger diameter threads have a larger5 c circumference for 5 d larger amounts of water to congregate on andcling to than is found available on the 5 sc smaller circumference ofthe smaller threads. This may explain the three new properties: 1. Anintrinsic ability to capture and redirect water flow, 2. An intrinsicability to either rapidly set well or allow for oil to be displaced bydownward flowing water, and 3. An intrinsic ability to rapidly dry.Additionally, air spaces or bridges existent between smaller diameterthreads spaced the same is larger diameter threads offers smaller wateradhesive sidewalls or water adhesive 5 c thread circumferences for waterto cling to making it more likely for water to drop downward. In myprior art I realized and taught that water directing planes contactingthe underside of micro screen capture and redirect water mosteffectively when the tops of those planes employ certain shapes and whenthe top of the planes tend toward narrow rather than wide dimensions. Ibelieve that the smaller circumference of the smaller threads acts in asimilar manner by offering a more narrow point or plaintiff contactbetween the top surface of the thread and the underside of water dropsor sheets flowing over the thread. I do not, at this time, fullyunderstand why there is far less forward under flow of water clinging tothe bottom surface of “sheer” micro screens and cloth but have observedthat this desirable property is existent in “sheer” micro screens andcloth. Although every cause for the newly discovered properties existentin sheer micro screens that may be employed in fields 51/12 may not befully understood or identified what has been discovered and is nowtaught in the specification is that smaller than your threads allow forcloth or micro screens to exist in a plane whose vertical height variesonly slightly from thread to thread regardless of the type of weaveemployed. The more the vertical height between threads can be reducedthe more the properties disclosed in the specification become apparent.There are many methods of weaving metallic threaded cloth, those whichemploy crimping or other processes that reduce vertical height of thethread or thread junctures place threads more closely within the samehorizontal plane and these types of weaves are preferred for the presentinvention. To the best of my knowledge, this disclosure as well asothers taught within this specification have never been identified ortaught in prior art.

Referring to FIG. 23, it is shown that smaller diameter threads allowfor greater threads per inch thread count in a micro screen whilemaintaining the same open air space that would exist in a micro screenemploying fewer threads per inch with greater diameter. Testing hasshown that this type of sheer micro screen also outperforms largerthreaded micro screens possessing the same open air space when it comesto capturing and redirecting water flow, shedding oil or displacing oilin the presence of water flow, or rapidly drying.

It is understood that the present invention is not limited to anyparticular shape of thread. Threads with grooves, spiral grooves, orintermittent depressions or compressions serve to capture and channelwater in unique ways and such threads may be utilized within embodimentsdescribed within this specification. Threads of different compositionmay offer desirable features such as interweaving copper threads withstainless steel to thwart moss or mildew growth. Varying thread sizesmay allow for extremely sheer and high numbered thread count microscreens to be employed by this invention, for example: warp threads withdiameters of 0.057 mm could be employed at 120 threads per inch forstrength while weft threads of 0.03 mm diameter could be employed toachieve 300 threads per inch which may serve to screen or filter certainorganisms from entering a rain gutter/gutter guard combination utilizedfor rain harvesting.

Referring to (FIG. 24,25) 2 a 2 recessed, downwardly depressed orembossed channels or wells are shown existing within the body of a metalplane expanded horizontally to the long side. It is also illustratedthat elements 19 may be placed within these wells and then, referring toFIG. 25, overlain by filtration membrane 3 m. The preferred shape ofthese elements is round or oval since these shapes tend to capture waterthat contacts the top surface and directed downward. The elements may bezinc, copper, or other material that tends to release ions that preventmoss, mold, mildew, or other growth, or that aid in the filtration andpurification of water.

Referring to FIG. 26 there is illustrated an embodiment of the invention20 shaped as a water receiving and water directing reverse curve 22 thatincorporates on its underside a gutter guard element receiving channel23 and downward extending drip plane 24. The gutter guard element 25employs a water receiving plane composed of metal expanded horizontallyto the long side 26, a water receiving and water directing downwardextending inseam or channel 27 and a front plane 28 that rests on top ofthe top lip of a rain gutter. The expanded metal portion of gutter guardelement 25 is overlain by a filtration membrane 3 m.

Referring to FIG. 27 there is illustrated an embodiment of the invention20 a that incorporates at the rear of top plane 21 a male sleeve 21 athat inserts into, referring to FIG. 29, channel 31 a: a component ofgutter hanging assembly 31. Referring to FIG. 28 gutter hanger 29 isshown that employees to rear hanging clips: 29 a and 29 b. A fasteningelement or screw 30 is also shown.

Referring to FIG. 29 a gutter guard and rain gutter hanging assembly 31is shown attached to a fascia board 32. The gutter guard hangingassembly employs a top receiving channel 31 a and two which is inserted,Referring to FIG. 27 the rear male sleeve 21 a of embodiment 21 a of thepresent invention. Referring again to FIG. 29 assembly 31 is alsoillustrated as incorporating a lower receiving channel 31 b.

Referring to FIG. 30 gutter guard at gutter hanging assembly 31 is shownattached to a fascia board 32. Embodiment 20 a of the present inventionis shown installed beneath (referring also to FIG. 32 a roof structureby means of its rear male sleeve 21 a being inserted into receivingchannel 31 a.

It is also illustrated that a rain gutter 33 is installed by means ofgutter hanger 29 which utilizes rear clip 29 b to loop over an upwardextending plane 31 c of receiving channel 31 b.

Referring to FIG. 31 there is illustrated a illustration elementcomposed of a water receiving area 34 a, which is expanded metal orother porous structure overlain by filtration membrane, and alsocomposed of a solid plane 34 b integrally attached to 34 a. Integrallyattached to 34 b is downward extending water directing plane 34 c.

Reverse Curve with Insertable Filtration Element

Referring to FIG. 32 an embodiment of the present invention is showninstalled beneath a roof membrane or structure 35 and illustrating waterflow paths 5. Water 5 flows off the roof structure and contacts solidplane 21, which may be of any width and gauge of metal or material thatallows for either flexibility or strength or both. Plane 21 should havesufficient strength and stiffness to retain it's angle of installationonce installed. It is not necessary that the plane be solid: if it iscomprised of expanded metal of sufficient strength and stiffness toretain angle of install, then expanded metal or any other porousmaterial may be utilized to form plane 21. Plane 21 may also be somewhatflexible to allow the plane to be bent at different angles to match roofpitch, if desired, but the invention is not limited to this property.Water continues to flow forward and downward from plane 21 to waterreceiving plane 22 a which, as shown is composed of metal expandedhorizontally to the long side overlain by micro mesh or other filteringmembrane. In any instance where the complete volume of forward flowingwater is not directed downward through plane 22 a but continues to flowforward it will be received and redirected downward both through andaround reverse curve 22 if this curve is composed of metal expandedhorizontally to the long side and overlain by a filtering membrane. Thisproperty is unique in that prior art has not utilized or described thistype of water receiving area configured as a reverse curve that is waterpermeable across it's entire surface area: Curves with louvers orperforations or expanded metal or screens are found in prior art butnone is found that teach a combination of metal expanded horizontally tothe long side overlain by micromesh or any other filtering membrane.

Any amount of water that follows around reverse curve 22 will bedirected to contact the water receiving area of upward extending plane34 a where it will fall through and downward contacting solid plane 34 band continuing to flow down plane 34 c and into the underlying raingutter. Planes 34 a, 34 b, and 34 c comprise insertable filter element34 which is shown inserted into the filter element receiving channel ofembodiment 22 of the invention. Plane 34 b rests on the top lip of raingutter 34.

Referring to (FIG. 27) 20 b, this reverse curved embodiment of thepresent invention may employ a rear plane or sleeve 21 a that isperpendicular to Water Directing Drip Edge element 20 a. that may beinserted, referring to FIGS. 29 and 30 into receiving channel 31 a ofreceiving member 31.

Referring to FIG. 33 insertable element 34 may serve as a stand-alonegutter guard. In such an embodiment water receiving plane 34 a would beof greater length than is illustrated in (FIG. 21) and may be adjustedupward as needed. As a stand-alone gutter guard element 34 may employ afastening shelf 34 d integrally attached to water receiving area 34 a.Fastening members such as screws 30 may be used to secure 34 d to thetop lip of the rain gutter 33. The lower plane of 34 d would continue toextend downward into water directing planes 34 b which would reverseangle and extend downward into engaging plane 34 e. Engaging plane 34 ewould hook beneath upward extending plane 29 c which is an integralmember of gutter hanger 29.

REFERENCE NUMERALS

-   1 common expanded metal gutter guard-   1 a common vertical expanded metal pattern comprised of expanded    openings that have a vertical length greater than their horizontal    width as they traverse a length of slit expanded metal-   1 a 1 Expanded opening exhibiting a vertical height greater than    it's horizontal width-   1 b rear metal band-   1 c front metal band-   1 d rear metal plane-   1 e front metal band and downward securing member-   2 embodiment of the invention-   2 a horizontal expanded metal pattern comprised of expanded metal    openings that have a horizontal width greater than their vertical    length as they traverse a length of slit expanded metal-   2 a 1 expanded metal opening exhibiting a horizontal width greater    than it's vertical height-   3 exploded view of an expanded opening exhibiting a vertical height    greater than it's width-   3 a top surface of the upper right linear segment of a vertical    expanded metal opening-   3 b bottom surface of the right linear segment of a vertical    expanded metal opening-   3 c top surface of a mid linear segment “knuckle” of a vertical    expanded metal opening-   3 d bottom surface of a mid linear segment “knuckle” of a vertical    expanded metal opening-   3 e top surface of the lower right linear segment of a vertical    expanded metal opening-   3 f bottom surface of the lower right linear segment of a vertical    expanded metal opening-   3 g top surface of the lower left linear segment of a vertical    expanded metal opening-   3 h bottom surface of the lower left linear segment of a vertical    expanded metal opening-   3 i top surface of a mid linear segment “knuckle” of a vertical    expanded metal opening-   3 j bottom surface of a mid linear segment “knuckle” of a vertical    expanded metal opening-   3 k top surface of the upper left linear segment of a vertical    expanded metal opening-   3L bottom surface of the upper left linear segment of a vertical    expanded metal opening-   3 m sheer micro mesh or other filtration membrane-   3 mwarp threads positioned vertically In a cloth or screen-   3 mweft threads positioned horizontally in a cloth or screen-   3 mi Upward embossed “island” rising out of a downward embossed or    recessed rectangular shaped depression in the micro screen that    transverses the entire length of the micro screen-   3 msi upward embossed “islands” rising out of multiple separated    downward embossed or recessed rectangular shaped depressions present    in the micro screen cloth-   3 mst smaller diameter thread-   3 mt larger diameter thread-   3 mts top surface of micromesh or other filter membrane-   3 mr recessed rectangular shape transversing the length of the micro    screen-   3 msr separated segmented rectangular shape-   3 mdi downward extending inseam-   4 exploded view of an expanded opening exhibiting a linear width    greater than it's vertical height-   4 a top surface of the upper right linear segment of a vertical    expanded metal opening-   4 b bottom surface of the right linear segment of a vertical    expanded metal opening-   4 c top surface of a mid linear segment “knuckle” of a vertical    expanded metal opening-   4 d bottom surface of a mid linear segment “knuckle” of a vertical    expanded metal opening-   4 e top surface of the lower right linear segment of a vertical    expanded metal opening-   4 f bottom surface of the lower right linear segment of a vertical    expanded metal opening-   4 g top surface of the lower left linear segment of a vertical    expanded metal opening-   4 h bottom surface of the lower left linear segment of a vertical    expanded metal opening-   4 i top surface of a mid linear segment “knuckle” of a vertical    expanded metal opening-   4 j bottom surface of a mid linear segment “knuckle” of a vertical    expanded metal opening-   4 k top surface of the upper left linear segment of a vertical    expanded metal opening-   4L bottom surface of the upper left linear segment of a vertical    expanded metal opening-   4 m segment of an expanded metal opening that has been corrugated-   4 n horizontal width of expanded opening expanded horizontally to    the longside-   4 o vertical height of expanded opening expanded horizontally to the    longside-   4 p center member of an expanded metal opening-   ab° angle of degree-   s1 right upper sidewall of expanded metal opening-   s2 right lower sidewall of expanded metal opening-   s3 bottom sidewall or “knuckle” of expanded metal opening-   s4 left bottom sidewall of expanded metal opening-   s5 left upper sidewall of expanded metal opening-   s6 upper sidewall or “knuckle” of expanded metal opening-   5 water flow path-   5 a water flow path around curved and recessed, sidewall-   5 b water flow path around shaped and recessed sidewall-   5 c thread circumference-   5 d drops of water-   5 sp space between threads-   5 sc thread circumference of smaller diameter thread-   6 rain gutter-   7 fascia board-   8 roof shingles-   9 heart shapes depressed or embossed downward into a metallic thread    micro screen-   10 animal footprints depressed or embossed downward into a metallic    thread micro screen-   11 bowtie shape depressed or embossed downward into a metallic    thread micro screen-   12 8 sided polygon shape depressed or embossed downward into a    metallic thread micro screen-   13 word phrase: “Alex Rules” depressed or embossed downward into a    metallic thread micro screen-   14 word phrase: “Karen Rules” depressed or embossed downward into a    metallic thread micro screen-   15 tapered recessed rectangular shape: part of a segmented pattern-   16 upraised emboss-   17 tapered recessed rectangular shape that is continuous and    unbroken-   18 continuous upraised emboss-   19 insertable element-   20 Water Directing Drip Edge element-   20 a Water Directing Drip Edge element with rear insertable sleeve-   20 b Embodiment of the invention illustrating a rear insertable    sleeve-   21 Rear Plane-   21 a Rear vertical plane serving as insertable sleeve-   22 Reverse curved plane composed of a “2 a” type of expanded metal    overlain by a filtration membrane-   22 a Water receiving plane-   23 receiving channel composed of 2 a type expanded metal overlain by    a filtration membrane-   24 downward extending drip edge composed of 2 a type expanded metal    overlain by A filtration membrane-   25 Gutter Guard element composed of 2 a type expanded metal overlain    by a filtration membrane-   2 a type expanded metal-   27 Downward extending inseam composed of 2 a type expanded metal    overlain by a filtration membrane-   28 front rain gutter engaging edge-   29 Gutter Hangar with 2 rear clips-   29 a Rear clip a-   29 b Rear clip b-   29 c upward extending clip-   30 Fastening member-   31 Gutter Mounting Rail-   31 a Gutter Guard receiving channel-   31 b Gutter Clip or Gutter Rear wall receiving channel-   31 c upward extending plane of 31 a-   32 fascia board-   33 rain gutter-   33 a front top lip of a rain gutter-   34 insertable filter-   34 a water receiving plane of insertable plane 34-   34 b lower solid plane of insertable filter 34-   34 c lower solid drip plane of insertable filter 34-   34 d roll formed double plane or extruded single plane that serves    as a fastening member for insertable filter 34-   34 f rear planar portion of insertable filter 34-   34 e downward extending engaging element of insertable filter 34-   D thread diameter-   rd rectangular recess, depression or emboss in the top surface of a    filter cloth or membrane-   S1-S8 Side wall members-   LS Longest sidewall member-   SS Shorter sidewall member-   SWD short way of the diamond: a term that indicates punched diamond    openings, that comprise expanded metal, have their shorter open air    spaces positioned parallel to the long edge of an expanded metal    sheet or roll.-   LWD long way of the diamond: a term that indicates punched diamond    openings, that comprise expanded metal, have their longer open air    spaces positioned parallel to the long edge of an expanded metal    sheet or roll.-   OWF Oncoming water flow

1. A rain gutter filtering assembly comprising: a screen or mesh havinga top surface and a bottom surface and first and second longitudinaledges extending between opposing ends overlying an expanded metalskeletal structure wherein the expanded metal is formed with openingsperimetered by sidewall members angled toward oncoming water flowwherein at least one of the openings has a majority of its sidewallmembers angled toward oncoming water flow, said opening having at leastone of the sidewall members angled toward water flow being perpendicularor almost perpendicular to oncoming water flow and of a greater lengththan the majority of remaining sidewall members that perimeter saidopening.
 2. The gutter assembly according to claim one wherein thesidewall member relatively perpendicular or perpendicular to water flowand having a greater length than the majority of remaining sidewallmembers that define a perimetered opening has a top edge of narrowerwidth than its corresponding bottom edge.